Final Action Plan - JNS UP task force on the Great Belt Accident

Short term risk mitigation measures for pocket wagons equipped with hitch type FW6170.

When Who Action and tools Consequences Documentation

0) Maintenance ECM All ECMs (note 1) in charge of pocket wagons shall check whether their hitch maintenance (including lubrication (note 2)) intervals related to the king-pin locking match the instruction of the manufacturer and are optimized to the use of the wagons.

Necessary changes identified shall be assessed and implemented without delay.

Conclusions shall be duly justified (based on a risk analysis in accordance with CSM RA) and documented. The next hitch maintenance date shall be indicated on both sides of the pocket wagon (note 4) or shall be made available by the keeper by other means.

1) Optional: At arrival, after removing the semi-trailer or container from the pocket wagon (unloading).

Terminal * Visual checks in the terminal that… I. …the handles on both sides are in their end position;

II. …the hitch is free of damages, and III. …the wagon is not marked with a K-label (note 3).

Tools:

- appropriate lighting. - red tape. - K-label (if terminal is contracted by the RU

accordingly)

If any of the checks I., II. or III. returns a negative result

red tape shall be affixed on the hitch handles on both sides;

pocket wagon shall not be used for the transport of semi-trailers, and

RU shall be informed.

Traceability of checks I. to III. shall be assured. Documentation by email from the terminal to the RU.

When Who Action and tools Consequences Documentation

2) Before placing the semi-trailer on to the pocket wagon (loading)

Terminal * Checks in the terminal that…: a) …either the hitch maintenance label (note 4) or

other means indicate that the date for next periodical maintenance has not expired;

b) …the hitch is free of damages (visually); c) …all visible moving parts of the hitch are

lubricated (visually) as describe in SAF Holland maintenance and operating manual (note 2 contains the relevant excerpt of this manual);

d) …the handles on both sides can be pulled out and released (functional test) (note5);

e) …the handles on both sides cannot be pushed further into the hitch (after they have been released – see previous check d)) (functional test) (note 5);

f) …the “notch” on both sides is not visible (note 6) (visually), and

g) …the hitch height is correctly adjusted to the semi-trailer to be placed on the pocket wagon.

Example for checks a) to g) is given in note 5. Tools:

- appropriate lighting. - hand light. - red tape. - K-label (if terminal is contracted by the RU

accordingly)

If any of the checks a) to g) returns a negative result

red tape (terminal) shall be affixed on the hitch handles on both sides;

K label (RU) shall be affixed on both sides of the wagon;

pocket wagon shall not be used for the transport of semi-trailers, and

RU shall be informed. RU after becoming aware of negative results regarding checks a) to g) shall report to the ECM and to the Keeper if required by contract (e.g. GCU Appendix 4).

Traceability of checks a) to g) shall be assured. Documentation by email from the terminal to the RU.

When Who Action and tools Consequences Documentation

3) During placing the semi-trailer onto the pocket wagon (loading).

Terminal * A dedicated staff member, standing next to the pocket wagon, shall direct the crane driver or reach stacker operator. Therefore this dedicated staff member, standing next to the pocket wagon, in addition to the crane driver or reach stacker operator shall assure that the kingpin is placed into the guiding ring of the hitch and that there are no gaps between the hitch top plate and the semi-trailer plate (note 7).

4) Immediately after placing the semi-trailer onto the pocket wagon (loading)

Terminal * Checks in the terminal that...: h) …the king pin is placed into the guiding ring of the

hitch and that there are no gaps between the hitch top plate and the semi-trailer plate (note 7);

i) …the retaining notch of the handle is not visible on the loading side of the wagon (note 6) , and

j) …the king pin locking works correctly, by trying to push the handle back to its end position.

Tools:

- hand light. - red tape. - K-label (if terminal is contracted by the RU

accordingly)

If any of the checks h) to j) returns a negative result

red tape (terminal) shall be affixed on the hitch handles on both sides;

K label (RU) shall be affixed on both sides of the wagon;

pocket wagon shall not be used for the transport of semi-trailers, and

RU shall be informed. RU after becoming aware of negative results regarding checks h) to j) shall report to the ECM and to the Keeper if required by contract (e.g. GCU Appendix 4).

Traceability of checks h) to j) shall be assured. Documentation by email from the terminal to the RU.

When Who Action and tools Consequences Documentation

5) Before train departure

RU Checks pocket wagons loaded with semi-trailers that…: i. … the check performed by the terminal returned no

negative results; ii. … no hitches are marked with red tape

iii. …no wagons are marked with a K-label (note 3) iv. …the king-pin is correctly placed and locked, by trying

to push the handle back to locked position on both sides of the wagon.

v. …that the retaining notch of the handle is not visible on both sides of the wagon (note 6)

Tools:

- hand light - K-label

If any of the checks i. to v. returns a negative result…

…the semi-trailer shall be removed from the pocket wagon concerned or if not possible;

…the pocket wagon concerned shall be shunted out from the train consist;

In both cases, a K Label (note 3) shall be affixed on both sides of the pocket wagon concerned, if not yet present.

It is recommended to see also GCU Appendix 9 Annex 1 chapter 6.7. (note 3) The RU shall ensure that all wagons having red tape have a K label affixed on both sides. RU shall report to the ECM and to the Keeper if required by contract (e.g. GCU Appendix 4).

Traceability of checks i. to v. shall be assured.

* A contract between the RU and the terminal operator must be present, if these checks are done by the terminal operator. The checks must be controlled within the scope

of the RU´s safety management system, especially in regards of procedures to be applied, and qualifications of staff involved.

Note 1: ECM functions and their relations according to:

1) Commission Regulation (EU) No 445/2011 of 10 May 2011 on a system of certification of entities in charge of maintenance for freight wagons and amending

Regulation (EC) No 653/2007.

2) ERA Guide for the application of the Art 14 (a) of the Safety Directive and Commission Regulation (EU) No 445/2011 on a system of certification of entities in

charge of maintenance for freight wagons, Document ID: ERA-GUI-100, dated 08.07.2015.

Note: The ECM4 functions shall be under the control of ECM 1, even if it is

outsourced and certified. ECM4 to deliver “records on maintenance

performed” to ECM3 who report further to ECM2.

ECM1 is responsible and certified for the entire process

According to Section 4 of the Regulation 445/2011/EU, the maintenance system shall be composed of the following functions: (a/ aka ECM1) the management function, which supervises and coordinates the maintenance functions referred to in points (b) to (d) and ensures the safe state of the freight wagon in the railway system; The certified ECM is the one who performs this function and is responsible for the others through its SMS. (b/ aka ECM2) the maintenance development function, which is responsible for the management of the maintenance documentation, including the configuration management, based on design and operational data as well as on performance and return on experience; (c/ aka ECM3) the fleet maintenance management function, which manages the freight wagon’s removal for maintenance and its return to operation after maintenance; and

(d/ aka ECM4) the maintenance delivery function, which delivers the required technical maintenance of a freight wagon or parts of it, including the release to service documentation.

These 3 last functions are integrated in the maintenance system through a MANAGEMENT PROCESS (see the figure to the right).

Note 2: Lubrication

Periodic lubrication of the railcar hitch FW6170 is to be conducted at least every four months by using a water resistant, lithium based grease. We recommend a long-term pressure grease NLGI class 21 with MoS2 or, e.g. MOTOREX. The lubrication intervals must be adapted to the respective operating conditions, shorter and longer intervals are possible. Make sure that all moving parts are clean and adequately lubricated. Attention should be paid especially to the following lubrication points:

1. All parts of the locking mechanism

2. Bevel gear (every 8 months or if required)

3. Spindle 1 4. Outer surface of the lifting arms

5. Contact surface of sliding frame guide shaft 3

4

2

5 5

MAKE SURE ALSO LUBRICATE ALL MOVING PARTS

UNDER THE HITCH PLATE, NOT SHOWN ON THE

PICTURE

Notes: When cleaning the railcar hitch, environmentally harmful substances may be used. We point out that the corresponding current waste regulations of each country must be observed when disposing of this waste. We recommend the wearing of protective gloves

when working with lubricant.

Note 3: GCU Label K shall be applied to the wagon, indicating that the wagon may not be reloaded:

Note 4: Check the hitch maintenance label if present:

It is possible to affix a “Hitch maintenance label” to both sides of the wagon, adjacent to each hitch.

Example by VTG:

Note 5: Example of a procedure for functional (technical) check suggested by VTG:

Functional test for Wagon Hitch FW6170 on Sdggmrs(s)

Before Loading 1) Check when the last maintenance was carried out for the wagon hitch,

see period grid at the wagon. Is the interval since the last maintenance exceeded, do not load a trailer on the wagon and inform railway undertaking or VTG accordingly (see keeper contact details at the wagon).

2) Check the wagon hitch for visual defects or damages. If there are defects or damages do not load a trailer on the wagon and inform VTG accordingly (see keeper contact details at the wagon).

3) Check the wagon hitch for correct locking function in the cone. The locking bar must be able to be pulled out by the operating handle and after release of the handle be able to be fully pulled back by the springs into the hitch.

Check that the handle has reached the end position by trying to push the handle further inward

Notes

1) See the previous page for an example.

2) Visual damages could be e.g. a bent handle or a missing

spring.

3) Check from both sides: The handle must be easy to pull

out, and it must go back to its end position without

problems. The retaining notch must not be visible. See

note 6.

4) It is recommended to lift the hitch during this check, as it

is not feasible to inspect under the plate in this position

in lower position.

Examples of period grids: Hitch / Stützbock 6 Month / 6M

Sema 01.2019

A B

A = Workshop, shortcut B= last check

Hitch / Stützbock 4 Month / 4M

Sema 01.2019

A B

A = Workshop, shortcut B= last check

Workshop function: If the handle has not reached the end position by itself, check if dirt or grease hinders the movement or if there is a damage to the locking mechanism.

4) The wagon hitch should be well greased, by all visible moving parts. 5) The height adjustment of the wagon hitch should be positioned in the

desired height for the next loading and must be locked (Indicator fully under the square block - for a detailed description see separate manual).

Note 6: Visually check that the handle is not in its open position

Illustrations

Pictures of a modified handle in open position.

The operating handle shall be retracted and the retaining notch must not be visible.

Note 7: Visually check that the semitrailer is loaded correctly and the kingpin is in the right position inserted into the guide ring